Catalytic Reactor Simulation

AltaSim Technologies guides engineers through multiphysics simulations so they can bring their products to market more rapidly, at a lower cost, and with an optimized design. To help see how working with AltaSim impacts our clients, we have put together a brief case study of how our simulation experts provided a unique solution in a recent project.


A client of AltaSim’s designs and manufactures systems that convert gas into multiple products through a catalytic reactor. The reactor produces a synthesis reaction from gas flowing through a porous catalytic media and includes cooling channels from flowing fluids to help control temperature. By modifying the operating conditions, our client wanted to improve efficiency and output capacity for their reactor, understanding that certain operating conditions would produce unstable reactions that would lead to reactor failure.


Our client came to AltaSim for our extensive expertise in developing multiphysics simulations. By creating virtual prototypes of their reactor design, AltaSim was able to assess different operating conditions and identify conditions that would likely to lead to an unstable reaction. The simulations also quantified the effects of detailed design variables for the reactor. Ultimately, AltaSim helped our client improve the efficiency of their design and operating conditions, without the need to build prototypes and test them at unsafe operating conditions.


Through simulation, our client was able to safely and inexpensively, assess operating conditions for improved efficiency in their design. For less than $20,000, our client was able to develop improved operating conditions that increased the value of their reactors by more than $100,000 per unit.

In addition to solving complex engineering challenges for our clients, AltaSim also trains engineers to develop simulations that answer their challenges. For more information on our classes visit our calendar.

We limit our classes to eight (8) students to maximize the attention each student receives. This limit causes our classes to fill up quickly. Our next available class for computational fluid mechanics will be in August. To learn more about this course, click here.

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July 2022 Case Study